Battery module

Abstract

The utility model discloses a composite thermal barrier and a related battery module, battery pack and thermal barrier. An apparatus may include a plurality of battery cells. An apparatus may include at least one thermal barrier for separating selected cells of the plurality of cells, the thermal barrier including an insulator layer; and a dielectric enhancement layer.

Description

TECHNICAL FIELD

[0001] The present disclosure generally relates to materials and systems and methods for preventing or mitigating thermal events (e.g., thermal runaway issues) in energy storage systems. In particular, the present disclosure provides thermal barrier materials. The present disclosure also relates to battery modules or packs having one or more battery cells comprising the thermal barrier materials, and systems comprising these battery modules or packs. The generally described examples can include aerogel materials. BACKGROUND

[0002] Lithium-ion batteries (LIBs) are widely used to power portable electronic devices such as cell phones, tablets, laptops, power tools, and other high-current devices such as electric vehicles due to their high operating voltage, low memory effect, and high energy density compared to conventional batteries. However, safety is an issue because LIBs are prone to catastrophic failure under “abuse conditions,” such as when a rechargeable battery is overcharged (charged beyond the design voltage), over-discharged, operated at high temperature and high pressure, or exposed to high temperature and high pressure. While the example of LIBs is used, the techniques of the present disclosure can be used with any type of battery.

[0003] To prevent the occurrence of cascading thermal runaway events, effective insulation and heat dissipation strategies are needed to address these and other technical challenges of LIBs. UTILITY

[0004] The utility model discloses a battery module, its characterized in that, include: a plurality of battery cells, be located in module shell, each battery cell has corresponding battery cell transverse footprint, at least one thermal barrier is used for separating selected battery cell in the plurality of battery cells, at least one thermal barrier includes core insulator layer and dielectric edge seal is used for closing one or more edges of core insulator layer. BRIEF DESCRIPTION OF DRAWINGS

[0005] Figure 1A A battery module is shown in accordance with some aspects.

[0006] Figure 1B Another battery module is shown in accordance with some aspects.

[0007] Figure 2 A thermal barrier is shown in accordance with some aspects.

[0008] Figure 3 Another thermal barrier is shown in accordance with some aspects.

[0009] Figure 4 Another thermal barrier is shown in accordance with some aspects.

[0010] Figure 5 Another thermal barrier is shown in accordance with some aspects.

[0011] Figure 6A Another thermal barrier is shown in accordance with some aspects.

[0012] Figure 6B A battery module is shown in accordance with some aspects.

[0013] Figure 6C A cross-sectional view of a battery module is shown in accordance with some aspects.

[0014] Figure 6D Another cross-sectional view of a battery module is shown in accordance with some aspects.

[0015] Figure 7A Another thermal barrier is shown in accordance with some aspects.

[0016] Figure 7B A cross-sectional view of a thermal barrier is shown in accordance with some aspects.

[0017] Figure 7C Another cross-sectional view of a thermal barrier is shown in accordance with some aspects.

[0018] Figure 8A Another cross-sectional view of a thermal barrier is shown in accordance with some aspects.

[0019] Figure 8B Another cross-sectional view of a thermal barrier is shown in accordance with some aspects.

[0020] Figure 9A Another thermal barrier is shown in accordance with some aspects. Figure 9B A close-up view of an edge seal of a dielectric enhancement layer is shown in accordance with some aspects. Figure 9C An end view of a thermal barrier is shown in accordance with some aspects.

[0021] Figure 10A Another thermal barrier is shown in accordance with some aspects. Figure 10B A close-up view of an edge seal of a dielectric enhancement layer is shown in accordance with some aspects. Figure 10C An end view of a thermal barrier is shown in accordance with some aspects.

[0022] Figure 11A Another thermal barrier is shown in accordance with some aspects. Figure 11B A close-up view of an edge seal of a dielectric enhancement layer is shown in accordance with some aspects. Figure 11C An end view of a thermal barrier is shown in accordance with some aspects.

[0023] Figure 12A Another thermal barrier is shown in accordance with some aspects.Figure 12B A close-up view of a thermal barrier edge is shown in accordance with some aspects. Figure 12C An end view of a thermal barrier is shown in accordance with some aspects.

[0024] Figure 13A An isometric exploded view of a battery module is shown in accordance with some aspects.

[0025] Figure 13B A selected cross-section of a thermal barrier and a housing portion is shown in accordance with some aspects.

[0026] Figure 14 An isometric exploded view of a battery module is shown in accordance with some aspects.

[0027] Figure 15A An end view of another thermal barrier and battery cell is shown in accordance with some aspects.

[0028] Figure 15B An end view of another thermal barrier and battery cell is shown in accordance with some aspects.

[0029] Figure 15C An isometric view of another thermal barrier is shown in accordance with some aspects.

[0030] Figure 16A An exploded view of another thermal barrier is shown in accordance with some aspects.

[0031] Figure 16B An exploded view of another thermal barrier is shown in accordance with some aspects.

[0032] Figure 16C An exploded view of another thermal barrier is shown in accordance with some aspects.

[0033] Figure 17A An end view of another thermal barrier is shown in accordance with some aspects.

[0034] Figure 17B An end view of another thermal barrier is shown in accordance with some aspects.

[0035] Figure 17C An end view of another thermal barrier is shown in accordance with some aspects.

[0036] Figure 17D An exploded view of another thermal barrier is shown in accordance with some aspects.

[0037] Figure 18 A cross-sectional view of a battery module is shown in accordance with some aspects

[0038] Figure 19 An electronic device is shown in accordance with some aspects.

[0039] Figure 20An electric vehicle is shown in accordance with some aspects.

[0040] 100: battery module

[0041] 102: battery cell

[0042] 104: electrical terminal, terminal

[0043] 110: thermal barrier

[0044] 112: battery cell sub-portion

[0045] 114: battery cell sub-portion

[0046] 150: battery module

[0047] 152: battery cell

[0048] 154: heat sink

[0049] 160: thermal barrier

[0050] 200: thermal barrier

[0051] 202: insulator layer

[0052] 204: dielectric enhancement layer

[0053] 206: second dielectric enhancement layer, dielectric enhancement layer

[0054] 300: thermal barrier

[0055] 302: insulator layer

[0056] 304: dielectric enhancement layer

[0057] 306: second dielectric enhancement layer, dielectric enhancement layer

[0058] 310: extension

[0059] 400: thermal barrier

[0060] 402: insulator layer

[0061] 404: dielectric enhancement layer

[0062] 406: second dielectric enhancement layer, dielectric enhancement layer

[0063] 410: extension

[0064] 412: extension

[0065] 500: thermal barrier

[0066] 502: insulator layer

[0067] 504: dielectric enhancement layer

[0068] 506: second dielectric enhancement layer, dielectric enhancement layer

[0069] 510: first extension

[0070] 512: second extension

[0071] 600: thermal barrier

[0072] 602: insulator layer

[0073] 604: dielectric enhancement layer

[0074] 606: second dielectric enhancement layer, dielectric enhancement layer

[0075] 610: first extension

[0076] 612: second extension

[0077] 614: third extension

[0078] 616: fourth extension

[0079] 650: battery module

[0080] 652: battery cell

[0081] 654: module housing

[0082] 656: lid

[0083] 657: side space

[0084] 658: top space

[0085] 659: compartment

[0086] 700: thermal barrier

[0087] 702: insulator layer

[0088] 704: dielectric enhancement layer

[0089] 706: second dielectric enhancement layer, dielectric enhancement layer

[0090] 708: edge seal

[0091] 800: thermal barrier

[0092] 802: insulator layer

[0093] 804: layer

[0094] 806: layer

[0095] 808: edge seal

[0096] 810: dielectric enhancement layer

[0097] 812: adhesive layer

[0098] 820: thermal barrier

[0099] 822: insulator layer

[0100] 824: first side

[0101] 825: adhesive layer

[0102] 826: second side

[0103] 827: dielectric enhancement layer

[0104] 828: edge seal

[0105] 900: thermal barrier

[0106] 902: insulator layer

[0107] 904: edge seal

[0108] 906: dielectric enhancement layer

[0109] 909: crease

[0110] 910: close-up view

[0111] 912: joint

[0112] 914: gap

[0113] 920: end view

[0114] 950: thermal barrier

[0115] 952: insulator layer

[0116] 953: middle portion

[0117] 954: gap

[0118] 956: dielectric edge seal

[0119] 960: close-up view

[0120] 970: end view

[0121] 1000: thermal barrier

[0122] 1002: insulator layer

[0123] 1004: gap

[0124] 1006: dielectric edge seal

[0125] 1008: encapsulation layer

[0126] 1010: close-up view

[0127] 1050: thermal barrier

[0128] 1052: insulator layer

[0129] 1053: intermediate portion

[0130] 1054: gap

[0131] 1056: dielectric edge seal

[0132] 1058: encapsulation layer

[0133] 1060: close-up view

[0134] 1070: end view

[0135] 1100: battery module

[0136] 1102: battery housing, housing

[0137] 1104: first slot

[0138] 1106: recessed plate

[0139] 1107: second slot

[0140] 1108: lid

[0141] 1110: cooling plate

[0142] 1112: battery cell

[0143] 1113: vent

[0144] 1114: thermal barrier

[0145] 1116: secondary battery cell separator

[0146] 1120: view

[0147] 1121: recess

[0148] 1122: dimension

[0149] 1123: insulator layer, thermal barrier

[0150] 1124: dimension

[0151] 1130: view

[0152] 1131: recess

[0153] 1132: dimension

[0154] 1133: insulator layer, thermal barrier

[0155] 1134: dimension

[0156] 1140: view

[0157] 1141: recess

[0158] 1142: dimension

[0159] 1143: insulator layer, thermal barrier

[0160] 1144: dimension

[0161] 1150: view

[0162] 1151: recess

[0163] 1152: dimension

[0164] 1153: insulator layer, thermal barrier

[0165] 1154: dimension

[0166] 1200: battery module

[0167] 1202: battery housing, housing

[0168] 1204: first slot

[0169] 1206: top slot plate, slot plate, top plate

[0170] 1207: second slot

[0171] 1208: lid

[0172] 1212: battery cell

[0173] 1213: vent

[0174] 1214: insulator layer, thermal barrier

[0175] 1216: secondary battery cell separator

[0176] 1218: bottom slot plate, bottom plate

[0177] 1219: third slot

[0178] 1300: thermal barrier

[0179] 1301: insulator layer, core

[0180] 1302: battery cell

[0181] 1303: lateral battery footprint

[0182] 1304: projection line

[0183] 1306: dielectric edge seal

[0184] 1308: corner

[0185] 1310: encapsulation layer

[0186] 1350: thermal barrier

[0187] 1352: central portion

[0188] 1353: fourth edge

[0189] 1354: corner

[0190] 1356: dielectric edge seal

[0191] 1400: thermal barrier

[0192] 1402: insulator layer

[0193] 1403: dielectric enhancement layer

[0194] 1404: first side

[0195] 1406: second side

[0196] 1407: fold

[0197] 1408: edge seal

[0198] 1410: thermal barrier

[0199] 1412: insulator layer

[0200] 1413: dielectric enhancement layer

[0201] 1414: first side

[0202] 1416: second side

[0203] 1417: bottom side

[0204] 1418: edge seal

[0205] 1420: thermal barrier

[0206] 1422: insulator layer

[0207] 1423: dielectric enhancement layer

[0208] 1428: edge seal

[0209] 1500: thermal barrier

[0210] 1502: insulator layer

[0211] 1504: dielectric enhancement layer

[0212] 1506: dielectric enhancement layer

[0213] 1508: encapsulation layer

[0214] 1510: thermal barrier

[0215] 1512: insulator layer

[0216] 1514: dielectric enhancement layer

[0217] 1516: dielectric enhancement layer

[0218] 1518: encapsulation layer

[0219] 1520: thermal barrier

[0220] 1522: insulator layer

[0221] 1523: adhesive

[0222] 1524: dielectric enhancement layer

[0223] 1525: release layer

[0224] 1526: dielectric enhancement layer

[0225] 1527: adhesive

[0226] 1528: encapsulation layer

[0227] 1530: thermal barrier

[0228] 1532: insulator layer

[0229] 1533: adhesive

[0230] 1534: dielectric enhancement layer

[0231] 1535: release layer

[0232] 1536: dielectric enhancement layer

[0233] 1537: adhesive layer

[0234] 1538: encapsulation layer

[0235] 1600: battery module

[0236] 1602: battery cell

[0237] 1604: module housing, housing

[0238] 1605: heat sink

[0239] 1606: lid

[0240] 1608: top insulator layer

[0241] 1610: thermal barrier

[0242] 1700: electronic device

[0243] 1702: housing

[0244] 1710: battery module

[0245] 1712: circuitry

[0246] 1714: charging port

[0247] 1720: functional electronic device

[0248] 1800: electric vehicle

[0249] 1802: chassis

[0250] 1804: charging port

[0251] 1806: circuitry

[0252] 1810: battery module

[0253] 1820: drive motor

[0254] 1822: wheel DETAILED DESCRIPTION

[0255] The following description and drawings are illustrative of specific embodiments and are not intended to limit the scope of the application. Other embodiments can include structural, logical, electrical, process and other changes. Portions and features of some embodiments can be included in, or substituted for, portions and features of other embodiments. Embodiments described in the claims are encompassed by the scope of the claims as a whole.

[0256] The insulating materials, thermal conductor materials, elastic materials, etc. described in the examples below can be used in battery modules to separate individual battery cells or groups of battery cells in a battery device. The plurality of battery cells coupled together in the present disclosure is referred to as a battery module. However, the described devices and methods can be used in any of a variety of types of multi-battery cell arrangements, which can be referred to as battery packs, battery systems, etc.

[0257] The insulating materials described below can be used as a single heat-resistant layer, or in combination with other layers to provide additional functionality to a multi-layered configuration, such as mechanical strength, compressibility, heat dissipation / conduction, etc. The insulating layers described herein are responsible for reliably containing and controlling the flow of heat from heat-generating components in small spaces, and providing safety and preventing the spread of fire for such products in the fields of electronics, industry, and automotive technology.

[0258] In many aspects of the present disclosure, the insulating layer, by itself or in combination with other materials, functions as a flame / flame deflection layer to enhance the performance of heat containment and control. For example, the insulating layer, by itself, can be resistant to flame and / or hot gases, and further includes entrained particulate material that changes or enhances heat containment and control.

[0259] Aerogel

[0260] One example of a high-efficiency insulating layer includes aerogels. Aerogels describe a class of materials according to their structure, namely low density, open-cell structure, large surface area (typically 900 m 2 / g or higher), and sub-nanometer pore size. The pores can be filled with a gas, such as air. Aerogels can be distinguished from other porous materials by their physical and structural properties. While aerogel materials are exemplary insulating materials, the present disclosure is not limited thereto. Other layers of thermal insulating materials can also be used in aspects of the present disclosure.

[0261] Selected examples of aerogel formation and properties are described. In several examples, a precursor material is gelled to form a network of pores filled with solvent. The solvent is then extracted, leaving a porous matrix. A variety of different aerogel compositions are known, which can be inorganic, organic, and inorganic / organic hybrids. Inorganic aerogels are typically based on metal alkoxides, including materials such as silica, zirconia, alumina, and other oxides. Organic aerogels include, but are not limited to, polyurethane aerogels, resorcinol formaldehyde aerogels, and polyimide aerogels.

[0262] Inorganic aerogels can be formed from metal oxide or metal alkoxide materials. The metal oxide or metal alkoxide materials can be based on an oxide or alkoxide of any metal that can form an oxide. Such metals include, but are not limited to, silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, cerium, and the like. Inorganic silica aerogels are traditionally made by hydrolysis and condensation of silica-based alkoxides, such as tetraethoxysilane, or by gelation of silicic acid or water glass. Other related inorganic precursor materials for silica-based aerogel synthesis include, but are not limited to, metal silicates (e.g., sodium or potassium silicate), alkoxysilanes, partially hydrolyzed alkoxysilanes, tetraethoxysilane (TEOS), partially hydrolyzed TEOS, condensation polymers of TEOS, tetramethoxysilane (TMOS), partially hydrolyzed TMOS, condensation polymers of TMOS, tetra-n-propoxysilane, partially hydrolyzed and / or condensation polymers of tetra-n-propoxysilane, polyethylsilicate, partially hydrolyzed polyethylsilicate, monomeric alkylalkoxysilanes, bis-trialkoxylalkyl or aryl silanes, polyhedral silsesquioxanes, or combinations thereof.

[0263] In some embodiments of this disclosure, pre-hydrolyzed TEOS, such as SilbondH-5 (SBH5, SilbondCorp), with a water / silica ratio of about 1.9-2, can be used commercially available or can be further hydrolyzed before being added to the gelation process. Partially hydrolyzed TEOS or TMOS, such as polyethylsilicate (Silbond40) or polymethylsilicate, can also be used commercially available or can be further hydrolyzed before being added to the gelation process.

[0264] Inorganic aerogels may also include gel precursors containing at least one hydrophobic group, such as alkyl metal alkoxides, cycloalkyl metal alkoxides, and aryl metal alkoxides, which can impart or improve certain properties of the gel, such as stability and hydrophobicity. Inorganic silica aerogels may specifically include hydrophobic precursors, such as alkylsilanes or arylsilanes. Hydrophobic gel precursors can be used as primary precursor materials to form the framework of the gel material. However, hydrophobic gel precursors are more commonly used as co-precursors, combined with simple metal alkoxides to form amalgam aerogels. Hydrophobic inorganic precursor materials for the synthesis of silica-based aerogels include, but are not limited to, trimethylmethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, dimethyldiethoxysilane (DMDES), ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane (PhTES), hexamethyldisilazane, and hexaethyldisilazane. Any derivative of any of the above precursors can be used, and specifically, polymers with certain other chemical groups can be added to or crosslinked to one or more of the above precursors.

[0265] Organic aerogels are typically formed from carbon-based polymer precursors. Such polymeric materials include, but are not limited to, resorcinol-formaldehyde (RF), polyimide, polyacrylate, polymethyl methacrylate, acrylate oligomers, polyoxyethylene, polyurethane, polyphenols, polybutane, trialkoxysilyl-terminated polydimethylsiloxane, polystyrene, polyacrylonitrile, polyfurfural, melamine-formaldehyde, cresol-formaldehyde, phenol-furfural, polyethers, polyols, polyisocyanates, polyhydroxybenzene, polyvinyl alcohol dialdehyde, polycyanurate, polyacrylamide, various epoxy resins, agar, agarose, chitosan, and combinations thereof. As an example, organic RF aerogels are typically prepared by sol-gel polymerization of resorcinol or melamine with formaldehyde under alkaline conditions.

[0266] Organic / inorganic hybrid aerogels are primarily composed of organically modified silica ("ormosil") aerogels. These ormosil materials include an organic component covalently bound to a silica network. Ormosils are typically formed by the hydrolysis and condensation of an organically modified silane, R-Si(OX)3, with a traditional alkoxide precursor, Y(OX)4. In these formulas, X can represent, for example, CH3, C2H5, C3H7, C4H9; Y can represent, for example, Si, Ti, Zr, or Al; and R can be any organic fragment, such as methyl, ethyl, propyl, butyl, isopropyl, methacrylate, acrylate, vinyl, epoxide, etc. The organic component in ormosil aerogels can also be dispersed throughout the silica network or chemically bound to the silica network.

[0267] Aerogels can be formed from flexible gel precursors. Various flexible layers, including flexible fiber-reinforced aerogels, can be readily combined and shaped to yield preforms that can yield high compressive strength bodies along any of these axes when mechanically compressed along one or more axes.

[0268] One method of aerogel formation includes batch casting. Batch casting includes catalyzing an entire volume of sol to induce gelation throughout the volume simultaneously. Gelation techniques include adjusting the pH and / or temperature of a dilute metal oxide sol to the extent that gelation occurs. Suitable materials for forming inorganic aerogels include oxides of most metals that can form oxides, such as silicon, aluminum, titanium, zirconium, hafnium, yttrium, vanadium, etc. Particularly preferred are gels formed primarily from alcoholic solutions of hydrolyzed silicates, due to their ready availability and low cost (alcoholic gels). Organic aerogels can also be made from melamine formaldehyde, resorcinol formaldehyde, etc.

[0269] In one example, the aerogel material can be monolithic, as well as continuous, throughout the entire structure or layer. In other examples, the aerogel material can include a composite aerogel material, in which aerogel particles are mixed with a binder or carrier. Other additives can be included in the composite aerogel material, including but not limited to surfactants that aid in the dispersion of the aerogel particles within the binder or carrier. The composite aerogel slurry can be applied to a support sheet (e.g., a mesh, felt, web, etc.) and then dried to form a composite aerogel structure.

[0270] Reinforcement

[0271] As noted above, the aerogel can be organic, inorganic, or a mixture thereof. In some examples, the aerogel comprises a silica-based aerogel. One or more layers in the thermal barrier can comprise a reinforcing material. The reinforcing material can be any material that provides elasticity, compliance, or structural stability to the aerogel material. Examples of reinforcing materials include, but are not limited to, open-cell macroporous framework reinforcing materials, closed-cell macroporous framework reinforcing materials, open-cell membranes, honeycomb reinforcing materials, polymeric reinforcing materials, and fibrous reinforcing materials, such as discrete fibers, woven materials, nonwoven materials, needle-punched nonwovens, battings, webs, mats, and felts.

[0272] The reinforcing material can be selected from organic polymer-based fibers, inorganic fibers, carbon-based fibers, or combinations thereof. The inorganic fibers can be selected from glass fibers, rock fibers, metal fibers, boron fibers, ceramic fibers, basalt fibers, other inorganic fibers, or combinations thereof. The organic polymer-based fibers can be selected from polyester polypropylene fibers, acrylic fibers, polyvinyl chloride fibers, aramid fibers, spandex fibers, nylon fibers, pre-oxidized fibers, pre-oxidized polyacrylonitrile (OPAN) fibers, other organic fibers, or combinations thereof. In some examples, the reinforcing material can comprise a multi-layer material.

[0273] Dielectric Reinforcement Layer

[0274] The dielectric reinforcing layer provides mechanical strength to the thermal barrier, among other functions. Its low electrical conductivity can prevent accidental electrical shorting in the battery module or battery pack. The dielectric reinforcing layer comprises a dielectric material and a dielectric polymer. For example, the dielectric reinforcing layer can comprise a material selected from ceramics, glass, rubber, oil, paper, resins, epoxy resins, plastics, and polymers, such as polyethylene, polypropylene, polytetrafluoroethylene, polyvinyl chloride (PVC), PVC elastomeric materials, PVC rigid materials, other dielectric materials, and combinations thereof.

[0275] Alternatively, the dielectric reinforcing layer can comprise mica. Advantages of using mica as the dielectric reinforcing layer include low thermal conductivity and abundant availability of such materials at low cost. Mica also naturally exists in sheet or flake form, which provides good structural performance at low cost. Mica flakes have mechanical strength compared to powdered dielectric materials and provide the required reinforcement and encapsulation to the insulating layer. In one aspect, the dielectric reinforcing layer comprises mica particles that are bound together with a binder (e.g., a polymeric binder) to form a structural sheet. In one aspect, the dielectric reinforcing layer is flexible. In one aspect, the binder can comprise a silicon-based polymer, although the disclosure is not limited thereto. Silicon polymers have the advantage of high heat resistance and low thermal conductivity.

[0276] Thermal Conduction

[0277] In addition to the thermal insulation layer, the thermally conductive layer in combination with the thermal insulation layer can effectively direct unwanted heat to a desired external location, such as an external heat sink, heat dissipating enclosure, or other external structure, to dissipate the unwanted heat to the external ambient air. In one example, one or more thermally conductive layers help dissipate heat from localized heat loads within the battery module or battery pack. Examples of high thermal conductivity materials include carbon fibers, carbon nanotubes, graphene, graphite, pyrolytic graphite sheets, silicon carbide, metals (including but not limited to copper, stainless steel, aluminum, etc.), and combinations thereof.

[0278] To help distribute and remove heat, in at least one embodiment, the thermally conductive layer is coupled with a heat sink. It should be understood that there are various heat sink types and configurations, as well as different techniques for coupling a heat sink to a thermally conductive layer, and the present disclosure is not limited to the use of any one heat sink / coupling technique. For example, at least one thermally conductive layer of the multi-layer material disclosed herein can be in thermal communication with an element of a cooling system of a battery module or pack, such as a cooling plate or cooling channel of the cooling system. As another example, at least one thermally conductive layer can be in thermal communication with other elements of a battery pack, battery module, or battery system that can function as a heat sink, such as a wall of the pack, module, or system, or with other multi-layer materials disposed between battery cells. Thermal communication between the thermally conductive layer and a heat sink element within the battery system can dissipate excess heat from one or more battery cells in the vicinity of the multi-layer material to the heat sink, thereby reducing the impact, severity, or spread of a thermal event that can generate excess heat. In addition to dissipating heat, the thermally conductive layer can also spread or dissipate heat from a high heat concentration area to a larger area with a lower heat concentration.

[0279] The thermally conductive layer can also replace the dielectric reinforcement layer in applications where thermal conduction is desired, in addition to serving a mechanical function of supporting other layers in the thermal barrier.

[0280] Elastic Material

[0281] In addition to the thermal insulation layer and the thermally conductive layer, one or more layers of a resilient material can also be included in the vicinity of the battery cells or between the battery cells. In one example, the resilient layer absorbs any volumetric expansion during normal operation of the one or more battery cells. For example, during charging, the battery cells can expand, while during discharging, the battery cells can contract. In one example, the resilient layer can also absorb permanent volumetric expansion caused by any battery cell degradation and / or thermal runaway. The resilient material layer can include, but is not limited to, foam, fiber, fabric, sponge, spring structure, rubber, polymer, etc.

[0282] Thermal Barrier with Extended Edges

[0283] Figure 1AOne example of a battery module 100 is shown. The module 100 includes a stack of battery cells 102. In one example, the stack of battery cells 102 includes lithium-ion battery cells 102, although other battery cell types are within the scope of the present disclosure. Several configurations of battery cells 102 are possible. In one example, the stack of battery cells 102 includes prismatic battery cells or pouch battery cells, although the present disclosure is not so limited. In one example, the stack of lithium-ion battery cells 102 includes lithium nickel manganese cobalt (NMC) oxide battery cells, although the present disclosure is not so limited. The plurality of battery cells 102 are grouped into a plurality of battery cell sub-portions 112, 114. As described above, it is desirable to stop or mitigate a thermal runaway condition that can occur in a battery cell, such as a lithium-ion battery cell 102. Thermal barriers 110 are shown in the figure between adjacent battery cell sub-portions 112, 114 to stop or mitigate thermal runaway between the battery cell sub-portions 112, 114.

[0284] Figure 1A Each of the battery cells 102 in the stack 102 includes electrical terminals 104. Although Figure 1A The example of FIG. 1 shows the battery cells 102 having terminals 104 on their top surface, although other configurations are within the scope of the present disclosure, including but not limited to other examples shown in the following figures.

[0285] The present disclosure refers to the “lateral footprint” of various components, including the battery cells 102 and the thermal barriers 110. The lateral footprint of a component refers to the area of the component’s major surface defined by the component’s perimeter. As Figure 1A As shown, the major surfaces of the battery cells 102 and the thermal barriers 110 are those in the Y-Z plane (see reference axes in Figure 1A For clarity and convenience of explanation, the term battery cell (equivalent to “battery” or “cell”) lateral footprint (“footprint”) refers to the battery cell’s major surface in the Y-Z plane. Similarly, the thermal barrier lateral footprint (“footprint”) refers to the thermal barrier’s major surface in the Y-Z plane. In some examples described below, the thermal barrier can be made of multiple laminated layers, each of which can have its corresponding lateral footprint (i.e., insulator lateral footprint, dielectric enhancement layer lateral footprint). For clarity, the “minor surface” refers to the surface orthogonal to the major surface and, using the reference coordinate axes in the figures, is in the X-Y plane.

[0286] Figure 1B An optional configuration of a battery module 150 is shown, which includes a heat sink 154 or cooling plate located on one side of the module 150 and in thermal communication with the battery cells 152. Figure 1BA cross-section of a battery module 150 is shown. One or more battery cells 152 are shown separated by one or more thermal barriers 160. Although in Figure 1B the disclosure is not limited thereto. In other examples, each battery cell 152 is surrounded by a thermal barrier 160. The side, bottom, or top surfaces of the battery module 150 can also include thermal barriers 160. Examples of thermal barriers 110, 160 are shown in more detail in the discussion of the figures below.

[0287] In Figure 1A and 1B the lateral footprint of the thermal barrier 110, 160 matches the lateral footprint of the battery cell 102. In other words, the lateral surface area of the thermal barrier 110, 160 is similar or identical to the lateral surface area of the battery cell itself. The thermal barrier 110, 160 does not extend beyond the lateral dimensions of the battery cell 102. The term “footprint” is used to illustrate the different battery cells not shown in the examples Figure 1A and 1B may include different lateral geometries other than rectangular or square. For example, pouch-style battery cells can generally be rectangular, but can have less well-defined contours. The less well-defined contours of the pouch-style battery cells will still define a lateral footprint, but the footprint can not be as completely defined by length times width as with rectangular battery cells.

[0288] Figure 2 An aspect of a thermal barrier 200 according to the disclosure is shown. Figure 2 The thermal barrier 200 of includes an insulator layer 202 and a dielectric reinforcement layer 204, which forms a laminate with the insulator layer 202. In one aspect, the dielectric reinforcement layer 204 is attached to the insulator layer 202, for example using an adhesive. The attachment of the dielectric reinforcement layer 204 is mechanically stronger than the insulator layer 202, thus providing structural support to the insulator layer 202. In one aspect, the insulator layer 202 includes an aerogel layer, although the disclosure is not limited thereto. Aerogel materials include very low thermal conductivity, while the addition of the dielectric reinforcement layer 204 provides the desired mechanical strength to the insulator layer 202 without adding an unnecessary higher thermal conductivity. The increased mechanical strength improves the durability of the thermal barrier 200, especially during particle bombardment under extreme conditions such as thermal runaway. The dielectric reinforcement layer 204 also serves as an encapsulation for the insulator layer 202 to reduce or prevent dust in the insulator layer 202.

[0289] In one aspect, the dielectric reinforcement layer 204 can be selected from polyvinyl chloride (PVC), a PVC elastomeric material, a PVC rigid material, rubber, other dielectric materials, and combinations thereof.

[0290] In one aspect, the dielectric reinforcement layer 204 includes mica. Advantages of using mica as the dielectric reinforcement layer include low thermal conductivity and abundant availability of such materials at low cost. Mica also naturally exists in sheet or sheet-like form, which provides good structural properties at low cost. Mica sheets have mechanical strength compared to powdered dielectric materials and provide the required reinforcement and encapsulation for the insulator layer 202. In one aspect, the dielectric reinforcement layer 204 includes mica particles that are bound together with an adhesive (e.g., a polymeric adhesive) to form a structural sheet. In one aspect, the dielectric reinforcement layer 204 is flexible. In one aspect, the adhesive can include a silicon-based polymer, although the present disclosure is not limited thereto. Silicon polymers have the advantage of high heat resistance and low thermal conductivity.

[0291] In some aspects, the insulator layer (e.g., 202, 302, 402, 502, 602, 702, 802, 822, 902, 952, 1002, 1052, 1123, 1133, 1143, 1153, 1214, 1301, 1402, 1412, 1422, 1502, 1512, 1522, 1532) can include a composite material of multiple layers. For example, the insulator layer can include a layer of insulation and other layers of material, such as a structural layer, a conductive layer, a compressible layer, an elastic layer, a dielectric layer, an adhesive layer, an expansion layer, a heat absorbing layer, a heat releasing layer, other suitable layers, or combinations thereof. In one example, the insulator layer can include a structural core layer and a layer of insulation disposed on both surfaces of the structural core layer. In one aspect, the insulator layer can include a structural core layer and a layer of insulation disposed on one major surface of the structural core layer.

[0292] In one aspect, the structural core layer can include the dielectric reinforcement layer and / or the thermal conduction layer described previously. In one example, the structural core layer can include a mica layer, a stainless steel layer, and / or a polymer layer.

[0293] In one aspect, the insulator layer can be a foam, fiberglass, non-woven, aerogel, aerogel composite, fiber-reinforced aerogel, other suitable insulating material, or combinations thereof. In other examples, the insulator layer can be a composite material, such as the composite materials disclosed in U.S. Patent Publication Nos. 2021 / 0163303, 2021 / 0167438, 2023 / 0032529, and U.S. Serial Nos. 18 / 571,175, 18 / 571,178, 18 / 571,172, each of which is incorporated by reference herein in its entirety.

[0294] In Figure 2In aspects, the thermal barrier 200 further includes a second dielectric enhancement layer 206. The second dielectric enhancement layer 206, the dielectric enhancement layer 204, and the insulator layer 202 in between form a sandwiched structure of the thermal barrier 200. The dielectric enhancement layers 204, 206 form a pair of dielectric enhancement layers on both major surfaces of the insulator layer 202. This configuration provides additional structural support to the insulator layer 202.

[0295] In an aspect, the one or more dielectric enhancement layers 204, 206 are attached to the insulator layer 202 using an adhesive. In an aspect, the adhesive includes a pressure sensitive adhesive (PSA). The PSA is useful because its use can simplify the manufacturing and assembly of the parts. Layers such as the dielectric enhancement layers 204, 206 and the insulator layer 202 can be attached by applying the PSA to the surface of one or more layers and pressing the layers together to activate the PAS. In an aspect, the PSA is included on all or a portion of one or more major surfaces of each dielectric enhancement layer 204, 206, but the disclosure is not limited thereto. The PSA on one major surface of the dielectric enhancement layer can help the dielectric enhancement layer attach to the insulator layer 202, while the PSA on the other major surface can help the dielectric enhancement layer attach to a battery cell (e.g., battery cell 102 or 152).

[0296] Figure 3 Another aspect of a thermal barrier 300 is shown. In this aspect, the thermal barrier 300 includes an insulator layer 302 and a dielectric enhancement layer 304 that forms a laminate with the insulator layer 302. Figure 3 In aspects, the thermal barrier 300 includes an insulator layer 302 and a dielectric enhancement layer 304 that forms a laminate with the insulator layer 302. In an aspect, a second dielectric enhancement layer 306 is included and a pair of dielectric enhancement layers 304, 306 are formed on both major surfaces of the insulator layer 302.

[0297] In aspects, the thermal barrier 300 includes an insulator layer 302 and a dielectric enhancement layer 304 that forms a laminate with the insulator layer 302. In an aspect, a second dielectric enhancement layer 306 is included and a pair of dielectric enhancement layers 304, 306 are formed on both major surfaces of the insulator layer 302. Figure 3 In the aspect shown, at least one of the dielectric enhancement layers 304 or 306 extends beyond the insulator lateral footprint, as shown by extension 310. The inclusion of one or more extensions 310 provides an enhanced barrier between adjacent battery cells in a battery module outside of the battery footprint. The one or more extensions 310 reduce or prevent the passage of heat or thermal runaway ejecta through the battery module. The function of the one or more extensions 310 is described in more detail below with respect to non-limiting extension geometries. Figure 6B The function of the one or more extensions 310 is described in more detail below with respect to non-limiting extension geometries.

[0298] Figure 4 Another aspect of a thermal barrier 400 is shown. In this aspect, the thermal barrier 400 includes an insulator layer 402 and a dielectric enhancement layer 404 that forms a laminate with the insulator layer 402. Figure 4In aspects, thermal barrier 400 includes an insulator layer 402 and a dielectric enhancement layer 404 that forms a laminate with the insulator layer 402. In one aspect, a second dielectric enhancement layer 406 is included and forms a pair of dielectric enhancement layers 404, 406 on both major surfaces of the insulator layer 402. In Figure 4 In aspects shown, one or more of the dielectric enhancement layers 404, 406 extend beyond the insulator lateral footprint in multiple dimensions. In Figure 4 In one aspect, the enhancement layers 404, 406 each extend laterally upward (Z direction) and from the sides (Y direction and negative Y direction) of the insulator layer. More specifically, in Figure 4 In the example shown, Figure 4 The dielectric enhancement layers 404, 406 are shown extending beyond the top dimension (Z direction) at extensions 410 and beyond the side dimension (Y direction) at extensions 412. In these aspects, the enhancement layers 404, 406 can extend beyond the footprint of the insulator layer so as to contact, engage, or otherwise interact with the sidewalls, floor, or ceiling of the module enclosure, as discussed in more detail below, to reduce or prevent heat or thermal runaway ejecta from passing through the battery module.

[0299] Figure 5 Another aspect of a thermal barrier 500 is shown. In Figure 5 In aspects, thermal barrier 500 includes an insulator layer 502 and a dielectric enhancement layer 504 that forms a laminate with the insulator layer 502. In one aspect, a second dielectric enhancement layer 506 is included and forms a pair of dielectric enhancement layers 504, 506 on both major surfaces of the insulator layer 502. In Figure 5 In aspects shown, one or more of the dielectric enhancement layers 504, 506 include one or more extensions that are angled outward away from the insulator layer. A first extension 510 of dielectric enhancement layer 504 is shown angled upward (positive Z direction) and to the right (positive X direction) relative to the insulator layer 502 that is coplanar with the Y-Z plane. A second extension 512 is shown angled upward (positive Z direction) and to the left (negative X direction) from the insulator layer 502. The first and second extensions 510 and 512 each form an angle Θ with the positive Z direction. The angle Θ can be an acute angle or a right angle. The angle Θ provides flexibility to the dielectric enhancement layers 504 and 506, for example, bending flexibility along the length of the extensions or at the intersection between the extensions and the main body of the enhancement layer. When the lid of the battery module is set in place, the angle increases (the first and second extensions 510 and 512 move downward in the negative Z direction), thus sealing the space between the battery cells and the lid. This function is explained further below in connection with Figure 6B

[0300] Figure 6A Another aspect of a thermal barrier 600 is shown. In​Figure 6A In aspects of the thermal barrier 600 includes an insulator layer 602 and a dielectric enhancement layer 604 forming a laminate with the insulator layer 602. In one aspect, a second dielectric enhancement layer 606 is included and formed on both major surfaces of the insulator layer 602.

[0301] In Figure 6A In the illustrated aspect, one or more dielectric enhancement layers 604, 606 are angled outward from the insulator layer. A first extension 610 of the dielectric enhancement layer 604 is angled upward (Z direction) and to the right (X direction) from the top edge of the insulator layer 602. A second extension 612 is angled upward (Z direction) and to the left (negative X direction) from the top of the insulator layer 602.

[0302] In addition, in Figure 6A one aspect, the enhancement layers 604, 606 each extend laterally upward and from the sides of the insulator layer 602 beyond the lateral footprint of the battery cell. More specifically, in Figure 6A the example, a third extension 614 is further shown as angled to the side and away from the side edge of the insulator layer 602. A fourth extension 616 is further shown as angled to the side and away from the side edge of the insulator layer 602. In one aspect, one edge of the extension 610 is connected to one edge of the extension 614 by a connector. In one aspect, the connector is triangular. The connector helps to prevent the passage of heat and particulates through the battery module during a thermal runaway event.

[0303] Figure 6B The use of the thermal barrier 600 in a battery module 650 is shown. A plurality of battery cells 652 are shown within the module housing 654. One or more of the battery cells 652 are separated by at least one thermal barrier 600. Figure 6B The thermal barrier 600 in Figure 6A is shown in the example, but other thermal barrier geometries described in this disclosure can also be configured as shown in the module 650 as shown in Figure 6B

[0304] As shown in Figure 6A the position of the extensions 610, 612 is such that the extensions 610, 612 extend into the top space 658 between the top of the battery cells 652 and the cover 656. The extensions 610, 612 divide the top space 658 into a plurality of independent compartments 659 that can better contain a flame and / or ejecta that can result from a failure of one or more of the battery cells 652.

[0305] As noted above, in Figure 6B ​In the example, extensions 610, 612 extend outward from the insulating layer 602 at an angle θ. In one aspect, angle θ is an acute angle or a right angle. In another aspect, the outward angle facilitates bending against the cover 656, thereby forming a better seal against any imperfections in the cover 656 and the spacing between the cover 656 and the battery cell 652. Compared to non-flexible extensions, the ability of extensions 610, 612 to bend and accommodate spacing differences forms a better seal with the cover 656.

[0306] Figure 6C It shows Figure 6B The image shows a cross-sectional view of the battery module 650 cut along line AA' of the insulating layer 602. The insulating layer 602 has an edge (e.g., a bottom edge) that contacts the bottom surface of the module housing 654 or a cooling plate (not shown) on the bottom surface. The top edge of the insulating layer 602 and the cover 656 are separated by a top space 658. The side edges of the insulating layer 602 and the sidewalls of the module housing 654 are separated by side spaces 657.

[0307] Figure 6D It shows Figure 6B A cross-sectional view of extensions 610 and 614 of the reinforcing layer 604 cut along line BB' in the battery module 650. Extensions 610 and 614 extend into the side spaces 657 and the top space 658, pressing against the cover 656 and sidewalls of the module housing 654 at an angle θ. Thus, extensions 610 and 614 separate the top space 658 and the side space 657 into independent compartments, thereby preventing heat or particles from passing through the side spaces 657 and the top space 658 during thermal runaway.

[0308] Thermal Barrier with Sealed Edges

[0309] Figure 7A Another aspect of the thermal barrier 700 with a sealed edge is shown. Figure 7B and 7C This is a cross-sectional view of the thermal barrier 700 along line CC'. Figure 7A and 7B In one aspect, the thermal barrier 700 includes an insulating layer 702 and a dielectric reinforcement layer 704, the dielectric reinforcement layer 704 forming a laminate with the insulating layer 702. In another aspect, a second dielectric reinforcement layer 706 is included, and a pair of dielectric reinforcement layers 704, 706 are formed on two primary surfaces of the insulating layer 702. An edge seal 708 is shown covering at least a portion of the periphery of the insulating layer 702 and the reinforcement layers 704, 706. That is, the edge seal 708 is disposed on at least a portion of one or more secondary surfaces of the thermal barrier 700 (i.e., Figure 7A (Surface in the XY plane).

[0310] In one aspect, the edge seal 708 includes an elastic material that deforms to provide an improved capped seal, as discussed above. Figure 6B As shown. In one aspect, the edge seal 708 is not resilient and provides a capped seal using only a close-fitting size. In one aspect, the edge seal 708 seals all four edges of the insulating layer 702. In one aspect, the edge seal 708 comprises tape or other adhesive film. For example, the tape or other adhesive film may be fixed to at least a portion of one or more secondary surfaces of the thermal barrier (i.e., Figure 7A (Surface in the XY plane). In some aspects, the edge seal may extend onto a portion of the main surface of the thermal barrier, for example, extending onto the surface of the reinforcing layer. In one aspect, the edge seal 708 includes a molded polymer channel. In one aspect, the polymer edge seal 708 includes rubber, silicone, resin, other elastic polymer materials, or combinations thereof.

[0311] exist Figure 7C The image shows an edge seal 720 that has been impregnated or painted. Advantages of the edge seal 720 include ease of manufacture and alternative polymer materials. Figure 7B Compared to the edge seal 708, the impregnated or painted edge seal 720 has a rounded edge. In one aspect, the edge seal 720 comprises an aerogel component (e.g., an aerogel coating), mica, other insulating or flame-retardant materials, or combinations thereof. In another aspect, the edge seal 720 comprises an expanding material. The advantage of an expanding material is that it expands when exposed to heat or flame above the activation temperature to form a better seal with the cover. As described above, the improved seal of the battery module cover can better contain runaway thermal events, thereby improving safety and enhancing protection of adjacent components.

[0312] Figure 8A and 8B Further aspects of thermal barriers 800 and 820 are shown, which may be incorporated into other thermal barriers in this disclosure. Thermal barrier 800 includes multiple layers 804 and 806 on two opposing principal surfaces of insulating layer 802. Figure 8A The image also shows an edge seal 808. Multiple layers can comprise several different layers, each playing a different role in the multilayer thermal barrier. Examples of layers include, but are not limited to, dielectric reinforcement layers, elastic layers, thermally conductive layers, adhesive layers, etc. Thermally conductive layers can be used to transfer heat from a given side of the thermal barrier to a heat sink or cooling plate, for example... Figure 1B Heatsink 154 in the middle. Figure 8A In one aspect, the plurality of layers 804 and 806 comprise an equal number of layers and may comprise layers of symmetrical type and sequence. In another aspect, the plurality of layers 804 and 806 each comprise a dielectric reinforcement layer 810 attached to the insulating layer 802 via an adhesive layer 812.

[0313] In Figure 8B one aspect, the thermal barrier 820 includes a plurality of layers on both opposing major surfaces of the insulator layer 822. Figure 8B An edge seal 828 is also shown in Figure 8B In the example shown, the plurality of layers on the first side 824 is asymmetric to the plurality of layers on the second side 826. Different layer orders, different material layers, and different numbers of layers can be used between the first side 824 and the second side 826 of the insulator layer 822 to better match the conditions at different locations between the battery cells within the battery module. In addition, reducing the number of layers can reduce the size and cost of the battery module.

[0314] In Figure 8B one aspect, the plurality of layers on the first side 824 includes a dielectric enhancement layer 827 attached to the insulator layer 822 by an adhesive layer 825. The plurality of layers on the second side 826 includes the adhesive layer 825. The thermal barrier 820 can be used at the end of a battery module where only one side of the thermal barrier 820 has a battery cell. The plurality of layers on the second side 826 having only the adhesive layer 825 and not the dielectric enhancement layer can be used to attach the thermal barrier 820 to an adjacent battery cell.

[0315] Figures 9A-9C Another aspect of a thermal barrier 900 is shown. The thermal barrier 900 includes a core 902. In one example, the core 902 includes a single layer of thermal insulating material, such as the insulator layer 202, 302, 402, 502, 602, 702, and 802 in Figures 2-8B In one example, the core 902 includes a plurality of layers. In one example, at least one of the plurality of layers includes a thermal insulating material. In one example, the thermal insulating material includes an aerogel material, but the present disclosure is not limited thereto. In one example, the thermal insulating material includes a reinforced aerogel material, such as a fiber-reinforced aerogel material or a foam-reinforced aerogel material. In selected examples, additional layers in the core 902 can include, but are not limited to, a thermal conductive layer (e.g., a metal layer), an encapsulation layer (e.g., a polymer film layer), etc. In one example, the core 902 is one of the thermal barriers 110, 160, 200, 300, 400, 500, 600, 700, or 800 in Figures 1A-8B In one example, the core 902 includes one or more layers selected from the layers of the thermal barriers 110, 160, 200, 300, 400, 500, 600, 700, or 800 in Figures 1A-8B In one example, the core 902 includes one or more layers selected from the layers of the thermal barriers 110, 160, 200, 300, 400, 500, 600, 700, or 800 in

[0316] In Figures 9A-9CIn the example of thermal barrier 900, the thermal barrier 900 further includes a dielectric enhancement layer 906 that encapsulates the core 902. The dielectric enhancement layer 906 includes edge seals 904 at the ends of the dielectric enhancement layer 906. The edge seals 904 cover the edges of the core 902. In one example, the dielectric enhancement layer 906 includes a material that is more robust than one or more layers of the core 902. In the example of aerogel thermal insulation material included in the core 902, the aerogel thermal insulation material can be prone to dusting, and / or can be easily broken during handling. The dielectric enhancement layer 906 is included to inhibit dusting, and to reduce damage to the core 902 from handling. One example of the dielectric enhancement layer 906 includes a mica-containing layer. In one example, the mica-containing layer has a degree of flexibility, and has a high degree of thermal insulation. The mica-containing layer can include a binder material, such as silicone or other polymer. Silicone has advantages because it has flexibility, and has a high degree of thermal insulation.

[0317] Figure 9B A close-up view 910 of the edge seals 904 of the dielectric enhancement layer 906 is further illustrated. The figure shows a piece of dielectric enhancement layer 906 wrapped around the core 902 and covering the entire surface of the core 902. There is a gap 914 between the edge seals 904 and the core 902. The gap 914 is filled with air, which acts as insulation to prevent the spread of heat and particulates to adjacent battery cells in the event of a thermal runaway. In some examples, the gap 914 can be filled with one or more other insulating materials, such as foam, intumescent material, electronic glass, ceramic, polymer, rubber, aerogel, air, oil, other insulating materials, or combinations thereof. In one example, a portion of the core 902 extends into the gap 914. For wrapped dielectric enhancement layer 906, a degree of flexibility is needed to facilitate wrapping. The figure shows a first edge seal 908A that forms a wrapping crease, and a second edge seal 908B where the ends of the wrapped dielectric enhancement layer 906 meet after wrapping at a connection or joint 912. Figure 9C A end view 920 of the thermal barrier 900 is further illustrated in FIG. 9B.

[0318] Figures 10A-10C Another aspect of a thermal barrier 950 is illustrated. The thermal barrier 950 includes a core 952. Similar to the example of thermal barrier 900, the core 952 includes a single layer of thermal insulation material, such as aerogel thermal insulation material 954. Figures 9A-9C Similar to the example of thermal barrier 900, in one example, the core 952 includes a single layer of thermal insulation material, such as aerogel thermal insulation material 954. Figures 2-8BThe insulating layers 202, 302, 402, 502, 602, 702, and 802 are used. In one example, core 952 includes multiple layers. In one example, at least one of the multiple layers includes a thermally insulating material. In one example, the thermally insulating material includes an aerogel material, but the invention is not limited thereto. In one example, the thermally insulating material includes a reinforcing aerogel material, such as a fiber-reinforced aerogel material or a foam-reinforced aerogel material. In selected examples, additional layers in core 952 may include, but are not limited to, thermally conductive layers (e.g., metal layers), encapsulation layers (e.g., polymer film layers), etc. In one example, core 902 is... Figures 1A-8B The thermal barrier is one of 110, 160, 200, 300, 400, 500, 600, 700, or 800. In one example, core 902 includes... Figures 1A-8B One or more layers selected from layers with thermal barriers of 110, 160, 200, 300, 400, 500, 600, 700 or 800.

[0319] exist Figures 10A-10C In one example, thermal barrier 950 includes a dielectric edge seal 956 surrounding the edge of core 952. A gap 954 is formed between the dielectric edge seal 956 and core 952. In some examples, gap 954 may be filled with another material, such as foam, expandable material, electronic glass, ceramic, polymer, rubber, aerogel, air, oil, other insulating materials, or combinations thereof. In one example, a portion of core 902 extends into gap 914. One advantage of reinforcing only the edge of core 952 includes reducing the amount of reinforcing material required. Another advantage of reinforcing only the edge of core 952 includes protecting only the edges that may break during handling. Another advantage of reinforcing only the edge of core 952 includes maintaining a thin thermal barrier 950 between battery cells while reinforcing portions of thermal barrier 950 exposed to and in contact with adjacent components, such as battery housing assemblies. Another advantage of reinforcing only the edge of core 952 includes manufacturing flexibility. By reinforcing only the edge of core 952, dielectric edge seal 956 can be applied to thermal barriers 950 in various region configurations. The only points of concern between different region configurations include selecting an appropriate length of dielectric edge seal 956 to cover the edge of core 952. Although in Figures 10A-10C The two opposing edges of the central core 952 are covered by dielectric edge seals 956, but the invention is not limited thereto. Three edges may also be reinforced, or all four edges may be reinforced.

[0320] Figure 10B A close-up view 960 of the dielectric edge seal 956 is further shown, which is depicted as wrapping around the edge of the core 952. Figure 10B In the example, a crease 909 is formed at one end of the dielectric edge seal 956.Figure 10C A cross-sectional view 970 of thermal barrier 950 is further shown. As discussed above, it can be advantageous to maintain a thinner middle portion of thermal barrier 950, which is located between battery cells. The middle portion 953 of thermal barrier 950 is shown in view 970, where middle portion 953 is thinner than the reinforced edge seal 956.

[0321] Figures 11A-11C Another aspect of a thermal barrier 1000 is shown. Thermal barrier 1000 includes a core 1002. Similar to other examples, in one example, core 1002 includes a single layer of thermal insulation material, such as the insulator layer 202, 302, 402, 502, 602, 702, and 802 in Figures 2-8B In one example, core 1002 includes multiple layers. In one example, at least one of the multiple layers includes a thermal insulation material. In one example, the thermal insulation material includes an aerogel material, although the present utility is not limited thereto. In one example, the thermal insulation material includes a reinforced aerogel material, such as a fiber-reinforced aerogel material or a foam-reinforced aerogel material. In selected examples, additional layers in core 1002 can include, but are not limited to, a thermally conductive layer (e.g., a metal layer), an encapsulation layer (e.g., a polymer film layer), and the like. In one example, core 902 is Figures 1A-8B In one example, core 1002 includes one or more layers selected from the layers of one of the thermal barriers 110, 160, 200, 300, 400, 500, 600, 700, or 800 in Figures 1A-8B In one example, core 1002 includes one or more layers selected from the layers of one of the thermal barriers 110, 160, 200, 300, 400, 500, 600, 700, or 800 in

[0322] In examples of Figures 11A-11C In one example, a portion of core 1002 extends into gap 1004. As discussed above with respect to other example configurations, it is advantageous to reinforce only the edges of core 1002. Although two opposing edges of core 1002 are shown in Figures 11A-11C Although two opposing edges of core 1002 are shown in

[0323] Figures 11A-11C A configuration of thermal barrier 1000 is also shown with an encapsulation layer 1008. In Figures 11A-11CIn one example, encapsulation layer 1008 covers all major surfaces of core 1002 and around the edges of core 1002. In another example, encapsulation layer 1008 covers the entire surface of core 1002. Encapsulation layer 1008 is shown as encapsulating dielectric edge seal 1006, along with other components of thermal barrier 1000, in a continuous sheet. Dielectric edge seal 1006 is disposed between core 1002 and encapsulation layer 1008. In one example, encapsulation layer 1008 comprises a flexible polymer sheet. Other flexible sheet materials are also within the scope of this invention. In one example, encapsulation layer 1008 is secured using pressure-sensitive adhesive strips, tapes, etc. In one example, encapsulation layer 1008 comprises an adhesive on all or part of one surface to provide an attachment mechanism to core 1002 and dielectric edge seal 1006. In one example, encapsulation layer 1008 is an adhesive layer, such as a pressure-sensitive adhesive layer.

[0324] Figure 11B A close-up view 1010 of the dielectric edge seal 1006 is further shown, which is depicted as wrapping around the edge of the core 1002, with a gap 1004 between them. Figure 11B In the example, encapsulation layer 1008 is shown covering core 1002 and dielectric edge seal 1006. Dielectric edge seal 1006 is disposed between core 1002 and encapsulation layer 1008. Figure 11C An end view 1020 of the thermal barrier 1000 is further shown. As mentioned above, it may be advantageous to maintain a thinner central portion of the thermal barrier 1000 (located between the battery cells). View 1020 shows the central portion 1003 of the thermal barrier 1000, wherein the central portion 1003 is thinner than the reinforcing edge of the core 1002.

[0325] Figures 12A-12C Another aspect of the thermal barrier 1050 is shown. The insulation layer 1050 includes a core 1052. Similar to other examples, in one example, the core 1052 includes a single layer of thermal insulation material, such as... Figures 2-8B The insulating layers 202, 302, 402, 502, 602, 702, and 802 are included. In one example, core 1052 includes multiple layers. In one example, at least one of the multiple layers includes a thermally insulating material. In one example, the thermally insulating material includes an aerogel material, but the invention is not limited thereto. In one example, the thermally insulating material includes a reinforcing aerogel material, such as a fiber-reinforced aerogel material or a foam-reinforced aerogel material. In selected examples, additional layers in core 1052 may include, but are not limited to, thermally conductive layers (e.g., metal layers), encapsulation layers (e.g., polymer film layers), etc. In one example, core 902 is... Figures 1A-8BThe thermal barrier is one of 110, 160, 200, 300, 400, 500, 600, 700, or 800. In one example, core 902 includes... Figures 1A-8B One or more layers selected from layers with thermal barriers of 110, 160, 200, 300, 400, 500, 600, 700 or 800.

[0326] exist Figures 12A-12C In the example, the thermal barrier 1050 includes a dielectric edge seal 1056 surrounding the edge of the core 1052. A gap 1054 is formed between the dielectric edge seal 1056 and the core 1052. As discussed above regarding other example configurations, reinforcing only the edges has many advantages. Although in Figures 12A-12C The diagram shows two opposing edges of core 1052 covered by dielectric edge seals 1056, but the invention is not limited thereto. Three edges may also be reinforced, or all four edges may be reinforced.

[0327] Figures 12A-12C The configuration also shows the encapsulation layer 1058. In Figures 12A-12C In one example, the encapsulation layer 1008 covers only the surfaces of the dielectric edge seal 1056 and the core 1052 adjacent to the dielectric edge seal 1056. In one example, the encapsulation layer 1058 comprises a flexible polymer sheet. Other flexible sheet materials are also within the scope of this invention. In one example, pressure-sensitive adhesive strips, tapes, etc., are used to secure the encapsulation layer 1058. In one example, the encapsulation layer 1058 comprises an adhesive on all or part of one surface to provide an attachment mechanism to the core 1052 and the dielectric edge seal 1056. In one example, the encapsulation layer 1058 comprises tape.

[0328] Figure 12B A close-up view 1060 further shows the edge of the thermal barrier 1050. The dielectric edge seal 1056 is shown wrapping around the edge of the core 1052. Figure 12B In the example, the encapsulation layer 1058 is shown to cover only the edge portion of the core 1052 and the dielectric edge seal 1056. Figure 12C An end view 1070 of the thermal barrier 1050 is further shown. As mentioned above, it may be advantageous to maintain a relatively thin middle portion of the thermal barrier 1050 (located between the cell cells). The middle portion 1053 of the thermal barrier 1050 is shown in view 1070, wherein the middle portion 1053 is thinner than the reinforcing edge.

[0329] Figure 13AA battery module 1100 is shown, which includes one or more thermal barriers as described in this disclosure. The battery module 1100 includes a plurality of battery cells 1112. The battery cells 1112 are configured to be located within a battery housing 1102. The battery module 1100 includes one or more thermal barriers 1114, which are similar to those described above. Figures 9A-12C The thermal barrier is described. Figure 13A In one example, cooling plate 1110 is included on one side of the stack of battery cells 1112. In a selected configuration, thermal barrier 1114 extends beyond the lateral footprint of battery cells 1112 on only three sides, thereby allowing cooling plate 1110 to contact thermal barrier 1114 on a fourth side. In one example, thermal barrier 1114 includes a heat-conducting plate within its core. In these examples, contact between the heat-conducting plate and cooling plate 1110 facilitates heat conduction between battery cells 1112 to cooling plate 1110 for dissipation or heat dissipation.

[0330] exist Figure 13A In the example, one or more slots are included to engage the thermal barrier 1114 and secure it within the housing 1102. In the event of a thermal runaway, gases and / or ejecta may escape from the vent 1113 or other locations on the battery cell 1112. Adding slots helps control any hot gases and / or ejecta. Figure 13A A first groove 1104 in the side wall of housing 1102 is shown. Although the groove 1104 is shown on the side of housing 1102, the groove may also be included on the bottom or cover of housing 1102. Figure 13A In the example, a recessed plate 1106 is included, which includes a plurality of second grooves 1107. The first groove 1104 and / or the second groove 1107 are positioned to align with and secure in place the thermal barrier 1114. Although the recessed plate 1106 is shown adjacent to the cover 1108, the invention is not limited thereto. The recessed plate 1106 may also be used near the bottom of the housing 1102 or on the side of the housing 1102.

[0331] Figure 13A One or more secondary battery cell separators 1116 are also shown. The secondary battery cell separators 1116 do not extend beyond the lateral cell footprint of the battery cell 1112. In one example, the secondary battery cell separator 1116 includes a heat-conducting plate. Although a combination of thermal barrier 1114 and secondary battery cell separator 1116 is shown, the invention is not limited thereto. Other examples include only one or the other of thermal barrier 1114 and secondary battery cell separator 1116.

[0332] Figure 13B The diagram illustrates several possible cross-sectional configurations of the slot, for example... Figure 13AThe first and second slots 1104 and 1107 are shown in view 1120. View 1120 shows a recess 1121. The recess 1121 includes a taper, where the top of the recess 1121 (e.g., the opening facing the interior of the housing) is wider than the bottom of the recess 1121 (e.g., the recess interior surface opposite the top). Dimension 1122 represents the width of the recess 1121 at the top. Dimension 1124 represents the width of the dielectric edge seal of the thermal barrier 1123. As shown, the tapered dimension 1122 helps to capture and align the thermal barrier 1123 during assembly.

[0333] View 1130 shows a recess 1131. The recess 1131 includes a geometry where the top of the recess 1131 is narrower than the bottom of the recess 1131. Dimension 1132 represents the width of the recess 1131 at the top. In one example, the recess 1131 includes a profiled cross-section that is substantially a mirror image of the cross-section of the dielectric edge seal of the thermal barrier 1133. Dimension 1134 represents the width of the dielectric edge seal (with encapsulation layer) of the thermal barrier 1133. As shown, dimension 1132 is slightly narrower than dimension 1134. The narrow top and profiled shape improve the retention of the thermal barrier 1133 within the recess 1131.

[0334] View 1140 shows a recess 1141. The recess 1141 includes a geometry where the top of the recess 1141 is more narrow than the bottom of the recess 1141. Dimension 1142 represents the width of the recess 1141 at the top. In one example, the recess 1141 includes a trapezoidal cross-section. The trapezoidal cross-section allows for more variation in the edge dimensions of the thermal barrier 1143 compared to the profiled cross-section of the recess 1131. Dimension 1144 represents the width of the dielectric edge seal of the thermal barrier 1143. As shown, dimension 1142 is slightly narrower than dimension 1144. The narrow top and trapezoidal cross-section improve the retention of the thermal barrier 1143 within the recess 1141.

[0335] View 1150 shows a recess 1151. The recess 1151 includes a geometry where the top of the recess 1141 is substantially the same as the bottom of the recess 1151. Dimension 1152 represents the width of the recess 1151 at the top and bottom. Dimension 1154 represents the width of the dielectric edge seal of the thermal barrier 1153. As shown, dimension 1152 is slightly wider than dimension 1154. This configuration facilitates easy positioning of the thermal barrier 1153 within the recess 1151, particularly when the dielectric edge seal of the thermal barrier 1153 is not very elastic and does not easily deform into the recess 1151.

[0336] Figure 14A battery module 1200 is shown that includes one or more thermal barriers as described in this disclosure. The battery module 1200 includes a plurality of battery cells 1212. The battery cells 1212 are configured to be located within a battery enclosure 1202. The battery module 1200 includes one or more thermal barriers 1214 that are similar to the thermal barriers described Figures 9A-12C above.

[0337] In Figure 14 examples, one or more slots are included to engage the thermal barriers 1214 and secure them within the enclosure 1202. In a thermal runaway event, gas and / or ejecta can be ejected from the vents 1213 or other locations on the battery cells 1212. The addition of slots helps to contain any hot gas and / or ejecta. Figure 14 A first slot 1204 included in a side wall of the enclosure 1202 is shown. Although the side of the enclosure 1202 is shown with slots 1204, slots can also be included on the bottom or lid of the enclosure 1202. In Figure 14 examples, a top slot plate 1206 is included in which a plurality of second slots 1207 are included in the slot plate 1206 adjacent to the lid 1208. A bottom slot plate 1218 is also shown in which a plurality of third slots 1219 are included in the bottom slot plate 1218. In one example, the bottom slot plate 1218 is a cooling plate. For example, a coolant flow can be included in the bottom slot plate 1218. The first slots 1204, the second slots 1207, and the third slots 1219 are positioned to align with and hold in place the thermal barriers 1214.

[0338] Figure 14 One or more secondary battery cell separators 1216 are also shown. The secondary battery cell separators 1216 do not extend beyond the lateral cell footprint (e.g., the largest surface of the battery cell) of the battery cells 1212. In one example, the secondary battery cell separators 1116 include a thermally conductive plate, and one or more of the top plate 1206 and the bottom plate 1218 are formed of metal or other conductor and function as a cooling plate. In one example, the thermal barriers 1214 extend beyond the lateral cell footprint of the battery cells 1212. Although a combination of the thermal barriers 1214 and the secondary battery cell separators 1216 are shown, the present disclosure is not limited as such. Other examples include only one or the other of the thermal barriers 1214 and the secondary battery cell separators 1216.

[0339] Figure 15AAnother example of a thermal barrier 1300 is shown. The thermal barrier 1300 is shown aligned with a battery cell 1302. A lateral battery footprint 1303 is shown by projection line 1304, within a middle portion of the thermal barrier 1300. Although only one thermal barrier 1300 and one battery cell 1302 are shown, it is understood that the configuration can be extended to a battery module with multiple thermal barriers 1300 and multiple battery cells 1302, as described in this disclosure.

[0340] In Figure 15A In an example, a dielectric edge seal 1306 is shown around the edges of the core 1301 of the thermal barrier 1300. In Figure 15A In an example, the corners 1308 of the core 1301 are not covered by the dielectric edge seal 1306. This configuration is easy to manufacture since the double thickness of the dielectric edge seal 1306 at the corners is avoided.

[0341] Figure 15B An end view of the thermal barrier 1300 is shown, with a battery cell 1302 located near the thermal barrier 1300. The core 1301 is shown with a dielectric edge seal 1306 located at the edges of the thermal barrier 1300. The battery cell 1302 is shown located within the lateral battery footprint 1303 (e.g., the maximum surface of the battery). The dielectric edge seal 1306 shown is thicker than the core 1301. The battery footprint is smaller than the maximum surface of the core 1301. A portion of the encapsulation layer 1310 above the dielectric edge seal 1306 is located between the battery cell 1302 and the core 1301, while the dielectric edge seal 1306 is located outside the footprint of the battery cell 1302. As described in other examples above, in this configuration, the edges of the thermal barrier 1300 are reinforced while still allowing the use of a thin thermal barrier 1300 within the lateral battery footprint 1303, resulting in a smaller overall size of the battery module.

[0342] In an example, the encapsulation layer 1310 extends to cover the entire lateral battery footprint 1303. In selected examples, portions of the tape, encapsulation layer, etc. that secure the dielectric edge seal 1306 are located within the lateral battery footprint 1303. The thickness of the encapsulation layer 1310 is significantly smaller than the dielectric edge seal 1306. Thus, the thermal barrier is thinner within the battery footprint 1303 and thicker outside the battery footprint 1303 to interface with the battery housing.

[0343] Figure 15C Another example of a thermal barrier 1350 is shown. A central portion 1352 of the thermal barrier 1350 is shown, which corresponds to a lateral battery footprint similar to the example shown in Figure 15A

[0344] In Figure 15C ​In the example, dielectric edge seal 1356 is shown around the three edges of the core of thermal barrier 1350. Figure 15C In the example, the core corner 1354 is covered by a dielectric edge seal 1356. This configuration eliminates any channels that might exist at the core corner, allowing gas and / or ejecta to escape through the thermal barrier 1350 in the event of thermal runaway. Figure 15C In the example, the fourth edge 1353 does not include any dielectric edge seal 1356. This configuration allows for thermal contact with the cooling plate, such as... Figure 13A As shown.

[0345] Thermal Barrier with Various Configurations of Dielectric Reinforcement Layers

[0346] Figure 16A Another aspect of the thermal barrier 1400 is shown. The thermal barrier 1400 includes an insulating layer 1402 and a dielectric reinforcement layer 1403, the dielectric reinforcement layer 1403 and the insulating layer 1402 forming a laminate. Figure 16A In the dielectric reinforcement layer 1403, there is a fold 1407 that forms a cap having a first side 1404 and a second side 1406. Figure 16A In one aspect, an edge seal 1408 similar to the aforementioned edge seal is also shown as an option. In one aspect, the edge seal 1408 seals three edges of the insulating layer 1402. The thermal barrier including the envelope structure has the advantages of easier edge control along the fold 1407 and reduced manufacturing costs.

[0347] Figure 16B Another aspect of the thermal barrier 1410 is shown. The thermal barrier 1410 includes an insulating layer 1412 and a dielectric reinforcement layer 1413. The dielectric reinforcement layer 1413 is U-shaped and has a first side 1414 and a second side 1416. The first side 1414 and the second side 1416 are connected by a bottom side 1417. The bottom side 1417 is perpendicular to the first side 1414 and the second side 1416. An edge seal 1418 seals the gap between the first side 1414 and the second side 1416, enclosing the insulating layer 1412 therebetween.

[0348] Figure 16C Another aspect of the thermal barrier 1420 is shown. The thermal barrier 1420 includes an insulating layer 1422 and a dielectric reinforcement layer 1423. The dielectric reinforcement layer 1423 has a groove with an opening in one of its surfaces, for example, forming a pocket. The insulating layer 1422 is inserted into the groove through the opening, for example, into a pocket. The thermal barrier 1420 also includes an edge seal 1428 to seal the insulating layer 1422 into the groove of the dielectric reinforcement layer 1423, for example, sealing the opening of a pocket.

[0349] Thermal Barrier with Dielectric Reinforcement Layer and Encapsulation Layer

[0350] Figure 17A A cross-sectional view of thermal barrier 1500 is shown. Thermal barrier 1500 includes an insulator layer 1502 and dielectric enhancement layers 1504 and 1506 on two opposing major surfaces of insulator layer 1502. Thermal barrier 1500 also includes an encapsulation layer 1508 that encases insulator layer 1502 to prevent or contain dust from insulator layer 1502. Encapsulation layer 1508 can completely or partially surround insulator layer 1502. In one aspect, encapsulation layer 1508 completely surrounds insulator layer 1502. Encapsulation layer 1508 is disposed between dielectric enhancement layers 1504 and 1506. Thermal barrier 1500 can also include an adhesive layer (not shown) between encapsulation layer 1508 and each of dielectric enhancement layers 1504 and 1506.

[0351] In one aspect, encapsulation layer 1508 can include a polyethylene (PE), a polypropylene (PP), a polyvinyl chloride (PVC), a polyethylene terephthalate (PET), a polycarbonate (PC), other polymers, a rubber or a resin film, or a combination thereof.

[0352] In one aspect, encapsulation layer 1508 can include an adhesive layer, such as a pressure sensitive adhesive (PSA). Encapsulation layer 1508 is pressed onto and completely surrounds insulator layer 1502. Dielectric enhancement layers 1504 and 1506 can be pressed onto and attached to both major surfaces of insulator layer 1502 by encapsulation layer 1508.

[0353] Figure 17B A cross-sectional view of thermal barrier 1510 is shown. Thermal barrier 1510 includes dielectric enhancement layers 1514, 1516 and an insulator layer 1512 therebetween. As with thermal barrier 1500, thermal barrier 1510 includes an encapsulation layer 1518 that encases insulator layer 1512 and dielectric enhancement layers 1514 and 1516. Figure 17A Unlike thermal barrier 1500, insulator layer 1512 and dielectric enhancement layers 1514 and 1516 are both encapsulated in encapsulation layer 1518. Encapsulation layer 1518 can prevent any possible dust on insulator layer 1512 or dielectric enhancement layers 1514 and 1516. Encapsulation layer 1518 can also be used to hold insulator layer 1512 and dielectric enhancement layers 1514 and 1516 without the use of an adhesive between them. In other aspects, enhancement layers 1514 and 1516 can be attached or adhered to insulator layer 1512, for example, using an adhesive, and encapsulation layer 1518 can be attached or adhered to the outer surface of thermal barrier 1510, for example, using an adhesive. In certain aspects, encapsulation layer can be attached or adhered only to itself, for example, by heat sealing or selective use of an adhesive on overlapping surfaces.

[0354] Figure 17CA cross-sectional view of thermal barrier 1520 is shown. Thermal barrier 1520 includes an insulator layer 1522 and two dielectric reinforcement layers 1524 and 1526 attached to insulator layer 1522 by adhesive 1523. In one aspect, adhesive 1523 is a spray adhesive, double-sided tape, or PSA.

[0355] Optionally, Figure 17C Thermal barrier 1520 in FIG. 15A can also include adhesive 1527 to attach to an adjacent battery cell (not shown). In one aspect, adhesive 1527 is double-sided tape, PSA, or spray adhesive. In one aspect, adhesive 1527 is in the shape of a plurality of stripes. In one aspect, adhesive 1527 is located at different locations on opposite surfaces of thermal barrier 1520 to reduce the stack height when multiple thermal barriers 1520 are used in a battery module.

[0356] In Figure 17C In certain aspects of FIG. 15A, adhesive 1527 and encapsulation layer 1528 are protected by release layer 1525, which can be removed to expose adhesive 1527 when thermal barrier 1520 is applied to a battery cell (not shown). In the case where encapsulation layer 1528 is a PSA, release layer 1525 is attached directly to encapsulation layer 1528 without adhesive 1527.

[0357] Figure 17D A exploded view of thermal barrier 1530 is shown. Thermal barrier 1530 includes an insulator layer 1532 and dielectric reinforcement layers 1534 and 1536. In one aspect, dielectric reinforcement layers 1534 and 1536 are attached to a major surface of insulator layer 1532 by adhesive 1533. Adhesive 1533 can cover the major surface of insulator layer 1532 completely or partially. In one aspect, adhesive 1533 can be an adhesive strip. In one aspect, the adhesive can be sprayed onto insulator layer 1532 or dielectric reinforcement layers 1534.

[0358] Figure 17D Thermal barrier 1530 in FIG. 16A can also include encapsulation layers 1538 that wrap insulator layer 1532 and dielectric reinforcement layers 1534 and 1536. At least one of encapsulation layers 1538 each includes a major surface and at least one flap 1539 adjacent to the major surface. In some aspects, one encapsulation layer has a major surface with a footprint that is the same as or smaller than insulator layer 1532 and dielectric reinforcement layers 1534 and 1536, while the other encapsulation layer includes at least one flap 1539. In various aspects, at least one flap 1539 can be folded to wrap around and contact the other encapsulation layer, thereby enclosing insulator layer 1532 and dielectric reinforcement layers 1534 and 1536.

[0359] Figure 17DThe thermal barrier 1530 in the battery module 1500 can also include an adhesive layer 1537 to attach the thermal barrier 1530 to the battery cells (not shown). The adhesive 1537 can be a double-sided tape or a spray-on adhesive. The adhesive layer 1537 can optionally be protected from external damage, such as scratches or dust, by a release layer 1535. The release layer 1535 is removable when the thermal barrier 1530 is applied to the battery cells (not shown). Figure 18 A battery module 1600 is shown that can include one or more thermal barriers as described in this disclosure. A number of battery cells 1602 are shown within the module enclosure 1604. One or more of the battery cells 1602 are separated by at least one thermal barrier 1610. In Figure 18 In the battery module 1600, a heat sink 1605 or cooling plate is included near one edge of the battery cells 1602 and the thermal barrier 1610. As described above, in one example, the one or more thermal barriers 1610 include a thermally conductive layer that facilitates lateral movement of heat to the heat sink 1605. A lid 1606 is shown that contains the battery cells 1602 and the thermal barrier 1610 within the enclosure 1604. In one aspect, a top insulator layer 1608 is included to prevent heat from escaping upward from the battery module 1600. In one aspect, the top insulator layer 1608 can withstand particle bombardment under extreme conditions (e.g., thermal runaway) to protect components (not shown) above the lid 1606. Examples of the top insulator layer 1608 include, but are not limited to, aerogel materials. In one example, the top insulator layer 1608 includes a similar structure as the thermal barriers described in this disclosure, such as a dielectric enhancement layer.

[0360] As described above, battery modules and / or battery packs with thermal barriers are used in a variety of electronic devices. Figure 19 An example electronic device 1700 is shown that includes a battery module 1710. The battery module 1710 is coupled to a functional electronic device 1720 by circuitry 1712. In the example shown, the battery module 1710 and the circuitry 1712 are contained within an enclosure 1702. A charging port 1714 is shown coupled to the battery module 1710 to facilitate charging of the battery module 1710 when needed.

[0361] In one example, the functional electronic device 1720 includes a device such as a semiconductor device with transistors and memory circuitry. Examples include, but are not limited to, a telephone, a computer, a display screen, a navigation system, etc.

[0362] Figure 20 Another electronic system is shown that utilizes a battery module that includes a thermal management system as described above. Figure 20An electric vehicle 1800 is shown. The electric vehicle 1800 includes a chassis 1802 and wheels 1822. In the example shown, each wheel 1822 is coupled to a drive motor 1820. A battery module 1810 is shown coupled to the drive motor 1820 by a circuit 1806. A charging port 1804 is shown coupled to the battery module 1810 in order to charge the battery module 1810 when needed.

[0363] Examples of electric vehicles 1800 include, but are not limited to, consumer vehicles such as cars, trucks, and the like. Commercial vehicles such as tractors and semi-trucks are also within the scope of the present disclosure. While four-wheeled vehicles are shown in the figures, the present disclosure is not so limited. For example, two-wheeled vehicles such as motorcycles and scooters are also within the scope of the present disclosure.

[0364] To better illustrate the methods and apparatus disclosed herein, a non-limiting list of embodiments is provided here:

[0365] Aspect 1. A battery module comprising: a plurality of battery cells; at least one thermal barrier to separate selected ones of the plurality of battery cells, the thermal barrier comprising an insulator layer; and a dielectric enhancement layer forming a laminate with the insulator layer.

[0366] Aspect 2. The battery module of aspect 1, wherein the dielectric enhancement layer comprises mica.

[0367] Aspect 3. The battery module of aspect 2, wherein the mica is contained in a silicone adhesive.

[0368] Aspect 4. The battery module of aspect 1, wherein the insulator layer comprises an aerogel.

[0369] Aspect 5. The battery module of aspect 1, wherein the dielectric enhancement layer comprises a pair of dielectric enhancement layers on both major surfaces of the insulator layer.

[0370] Aspect 6. The battery module of aspect 1, wherein the dielectric enhancement layer is attached to the insulator layer with an adhesive.

[0371] Aspect 7. The battery module of aspect 6, wherein the adhesive comprises a first pressure sensitive adhesive.

[0372] Aspect 8. The battery module of aspect 6, further comprising a second pressure sensitive adhesive to attach the thermal barrier to at least one of the battery cells.

[0373] Aspect 9. A battery module comprising: a plurality of battery cells within a module housing, the battery cells having a battery cell lateral footprint; a lid enclosing the module housing and covering the plurality of battery cells, wherein the lid defines a headspace between the plurality of battery cells and the lid; at least one thermal barrier separating selected ones of the plurality of battery cells, the thermal barrier comprising: an insulator layer having an insulator lateral footprint equal to or greater than the battery cell lateral footprint; and a reinforcement layer comprising a dielectric forming a laminate with the insulator layer, wherein the reinforcement layer comprising the dielectric extends beyond the insulator lateral footprint.

[0374] Aspect 10. The battery module of aspect 9, wherein the reinforcement layer comprises a pair of reinforcement layers on both major surfaces of the insulator layer.

[0375] Aspect 11. The battery module of aspect 10, wherein the reinforcement layer extends into the headspace.

[0376] Aspect 12. The battery module of aspect 9, further comprising a seal between the battery cells and the lid.

[0377] Aspect 13. The battery module of aspect 9, wherein the reinforcement layer extends laterally upward and from a side of the insulator layer.

[0378] Aspect 14. The battery module of aspect 9, further comprising a cooling plate adjacent to a bottom edge of the plurality of battery cells.

[0379] Aspect 15. The battery module of aspect 9, wherein the reinforcement layer is angled outward from the insulator layer.

[0380] Aspect 16. The battery module of aspect 9, wherein the insulator layer comprises aerogel.

[0381] Aspect 17. The battery module of aspect 9, wherein the reinforcement layer comprises mica.

[0382] Aspect 18. The battery module of aspect 9, further comprising a top thermal barrier between the plurality of battery cells and the lid.

[0383] Aspect 19. The battery module of aspect 18, wherein the top thermal barrier comprises an aerogel and mica laminate.

[0384] Aspect 20. A battery module comprising: a plurality of battery cells positioned within a module housing, the battery cells having a battery cell lateral footprint; a cover enclosing the module housing and covering the plurality of battery cells, wherein the cover defines a headspace between the plurality of battery cells and the cover; at least one layered thermal barrier separating selected ones of the plurality of battery cells, the thermal barrier comprising an insulator layer; a reinforcement layer comprising a dielectric forming a laminate with the insulator layer; and an edge seal, wherein the layered thermal barrier is sized such that the edge seal contacts the cover.

[0385] Aspect 21. The battery module of aspect 20, wherein the reinforcement layer comprises a pair of reinforcement layers positioned on both major surfaces of the insulator layer.

[0386] Aspect 22. The battery module of aspect 20, wherein the reinforcement layer comprises a sleeve having a fold.

[0387] Aspect 23. The battery module of aspect 20, wherein the cover comprises a top insulator layer adjacent a lower cover surface.

[0388] Aspect 24. The battery module of aspect 23, wherein the top insulator layer comprises an aerogel and a mica laminate.

[0389] Aspect 25. The battery module of aspect 20, wherein the insulator layer comprises an aerogel.

[0390] Aspect 26. The battery module of aspect 20, wherein the reinforcement layer comprises mica.

[0391] Aspect 27. The battery module of aspect 20, wherein the edge seal comprises a tape.

[0392] Aspect 28. The battery module of aspect 20, wherein the edge seal comprises an intumescent material.

[0393] Aspect 29. The battery module of aspect 20, wherein the edge seal is wider than a width of the insulator layer and the reinforcement layer.

[0394] Aspect 30. A thermal barrier comprising: an insulator layer; an encapsulation layer wrapping the insulator layer; and a dielectric reinforcement layer forming a laminate with the insulator layer and the encapsulation layer.

[0395] Aspect 31. The thermal barrier of aspect 30, wherein the encapsulation layer wraps the dielectric reinforcement layer.

[0396] Aspect 32. The thermal barrier of aspect 30, wherein the insulator layer and the dielectric reinforcement layer are separated by the encapsulation layer.

[0397] Aspect 33. The thermal barrier of aspect 30, wherein the encapsulation layer is an adhesive layer.

[0398] Aspect 34. The thermal barrier of Aspect 30, wherein the encapsulation layer is a pressure sensitive adhesive layer.

[0399] Aspect 35. The thermal barrier of Aspect 30, wherein the thermal barrier further comprises an adhesive layer between the insulator layer and the dielectric enhancement layer.

[0400] Aspect 36. The thermal barrier of Aspect 30, wherein the thermal barrier further comprises an adhesive layer over the encapsulation layer.

[0401] Aspect 37. The thermal barrier of Aspect 33, wherein the thermal barrier further comprises a release layer over the adhesive layer.

[0402] Aspect 38. The thermal barrier of Aspect 30, wherein the dielectric enhancement layer is a first dielectric enhancement layer disposed on one side of the insulator layer, and wherein the thermal barrier further comprises a second dielectric enhancement layer disposed on the other side of the insulator layer.

[0403] Aspect 39. A battery module comprising: a plurality of battery cells within a module housing, each battery cell having a corresponding battery cell lateral footprint; at least one thermal barrier separating selected ones of the plurality of battery cells, the at least one thermal barrier comprising: a core insulator layer; and a dielectric edge seal enclosing one or more edges of the core insulator layer.

[0404] Aspect 40. The battery module of Aspect 39, wherein the core insulator layer comprises an aerogel layer.

[0405] Aspect 41. The battery module of Aspect 39, wherein the dielectric edge seal comprises mica.

[0406] Aspect 42. The battery module of Aspect 39, further comprising an encapsulation layer covering the dielectric edge seal.

[0407] Aspect 43. The battery module of Aspect 39, further comprising an encapsulation layer covering the entire dielectric edge seal and the entire core insulator layer.

[0408] Aspect 44. The battery module of Aspect 39, wherein the dielectric edge seal covers the entire core insulator layer.

[0409] Aspect 45. The battery module of Aspect 42, wherein the encapsulation layer comprises a tape.

[0410] Aspect 46. The battery module of Aspect 39, wherein the dielectric edge seal encloses three edges, and a fourth edge of the thermal barrier contacts a cooling plate.

[0411] Aspect 47. The battery module of Aspect 39, wherein one or more sides of the housing comprise a recess corresponding to an edge of the at least one thermal barrier.

[0412] Aspect 48. The battery module of Aspect 47, wherein the top of the recess is narrower than the bottom of the recess.

[0413] Aspect 49. The battery module of Aspect 47, wherein the bottom of the recess is narrower than the top of the recess.

[0414] Aspect 50. The battery module of Aspect 47, wherein the recess comprises one or more recesses in the housing sidewall.

[0415] Aspect 51. The battery module of Aspect 39, further comprising one or more recessed plates contained within the housing.

[0416] Aspect 52. The battery module of Aspect 51, wherein the one or more recessed plates comprise a top recessed plate and a bottom recessed plate.

[0417] Aspect 53. The battery module of Aspect 39, wherein the dielectric edge seal encloses edges of the core insulator layer but does not enclose corners of the core insulator layer.

[0418] Aspect 54. The battery module of Aspect 39, wherein the dielectric edge seal encloses edges and corners of the core insulator layer.

[0419] Aspect 55. The battery module of Aspect 39, wherein the dielectric edge seal continuously spans three edges of the core insulator layer.

[0420] Aspect 56. The battery module of Aspect 39, wherein the dielectric edge seal covers a portion of the insulator layer laterally outside of the lateral footprint of the battery cell.

[0421] Aspect 57. The battery module of Aspect 39, wherein the battery module further comprises a secondary battery cell separator having a footprint smaller than the thermal barrier.

[0422] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) can be used in combination with each other. Other embodiments can be used, e.g., by those having ordinary skill in the art once the above description is made. This Abstract is included to comply with 37 C.F.R. § 1.72(b)

[0423] 1.72(b) so that the reader can quickly determine the nature of the technical disclosure. It should be understood that it is not intended to limit the scope or

[0424] While the summary of the utility new subject matter has been described with reference to particular example embodiments, various modifications and changes can be made to these embodiments without departing from the broader scope of the embodiments of the disclosure. Such embodiments of the utility new subject matter can be referred to herein individually or collectively as a utility new for convenience and are not intended to limit the scope of this application to any single disclosure or utility new concept, if more than one is, in fact, disclosed.

[0425] The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to practice the disclosed teachings. Other embodiments can be utilized and derived therefrom, such that structural and logical substitutions and changes can be made without departing from the scope of the disclosure. The detailed description is, therefore, not to be taken in a limiting sense. The scope of the various embodiments is defined by the appended claims, along with the full range of equivalents to which such claims are entitled.

[0426] As used herein, the term "or" can be construed in either an inclusive or exclusive sense. Moreover, multiple instances can be provided for resources, operations, or structures described herein as a single instance. Additionally, boundaries between various resources, operations, modules, engines, and data stores are somewhat arbitrary, and particular operations are shown as being performed by a particular instructional component for purposes of illustration only. Other functional

[0427] The foregoing description, for purposes of explanation, has been described with reference to specific illustrative embodiments. However, the illustrative discussions do not limit the possible examples to the precise forms described. Many modifications and variations are possible in view of the foregoing teachings. The example embodiments were chosen and described in order to best explain the principles of operation and their practical applications, to thereby enable others skilled in the art to best utilize the various example embodiments with various modifications as are suited to the particular uses contemplated.

[0428] It should also be understood that, although the terms “first,” “second,” etc. can be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of example embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

[0429] The terminology used in the description of the example embodiments herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used in the description of example embodiments and the appended examples, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “and / or,” as used herein, refer to and encompass any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0430] As used herein, the term “if’ can be construed to mean “when” or “in response to the occurrence of” or “in response to the detection of,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” can be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.

Claims

1. A battery module, characterized in that, Include: Multiple battery cells are located inside the module housing, and each battery cell has a corresponding lateral footprint. At least one thermal barrier for separating selected battery cells among the plurality of battery cells, the at least one thermal barrier comprising a core insulating layer; as well as Dielectric edge seals are used to seal one or more edges of the core insulating layer.

2. The battery module according to claim 1, characterized in that, The core insulating layer includes an aerogel layer.

3. The battery module according to claim 1, characterized in that, The dielectric edge seal includes mica.

4. The battery module according to claim 1, characterized in that, It also includes an encapsulation layer covering the dielectric edge seal.

5. The battery module according to claim 1, characterized in that, It also includes an encapsulation layer that covers the entire dielectric edge seal and the entire core insulating layer.

6. The battery module according to claim 1, characterized in that, The dielectric edge seal covers the entire core insulation layer.

7. The battery module according to claim 4, characterized in that, The encapsulation layer includes adhesive tape.

8. The battery module according to claim 1, characterized in that, The dielectric edge seal surrounds three edges, and the fourth edge of the thermal barrier contacts the cooling plate.

9. The battery module according to claim 1, characterized in that, One or more sides of the housing include grooves corresponding to the edge of the at least one thermal barrier.

10. The battery module according to claim 9, characterized in that, The groove is narrower at the top than at the bottom.

11. The battery module according to claim 9, characterized in that, The groove is narrower at the bottom than at the top.

12. The battery module according to claim 9, characterized in that, The groove includes one or more grooves in the sidewall of the housing.

13. The battery module according to claim 1, characterized in that, It also includes one or more recessed plates contained within the housing.

14. The battery module according to claim 13, characterized in that, The one or more recessed plates include top and bottom recessed plates.

15. The battery module according to claim 1, characterized in that, The dielectric edge seal surrounds the edge of the core insulating layer, but does not surround the corners of the core insulating layer.

16. The battery module according to claim 1, characterized in that, The dielectric edge seal surrounds the edges and corners of the core insulating layer.

17. The battery module according to claim 1, characterized in that, The dielectric edge seal extends continuously across the three edges of the core insulating layer.

18. The battery module according to claim 1, characterized in that, The dielectric edge seal covers the insulating layer laterally, located on a portion outside the lateral footprint of the battery cell.

19. The battery module according to claim 1, characterized in that, The battery module also includes a secondary battery cell separator with a smaller footprint than the thermal barrier.

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